Nanocomposite particle and process of preparing the same

ABSTRACT

A nanocomposite particle, its use as a catalyst, and a method of making it are disclosed. The nanocomposite particle comprises titanium dioxide nanoparticles, metal oxide nanoparticles, and a surface stabilizer. The metal oxide nanoparticles are formed hydrothermally in the presence of the titanium dioxide nanoparticles. The nanocomposite particle is an effective catalyst support, particularly for DeNO x  catalyst applications.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/502,678, filed Jul. 14, 2009, now U.S. Pat. No. 8,075,859, which is adivisional of U.S. patent application Ser. No. 11/509,339, filed Aug.24, 2006, now U.S. Pat. No. 7,820,583, the contents of each being herebyexpressly incorporated herein in their entirety by reference.

FIELD OF THE INVENTION

This invention relates to a nanocomposite particle and a process for itspreparation. The nanocomposite particle is useful as a catalyst and/or acatalyst support.

BACKGROUND OF THE INVENTION

Titanium dioxide is widely used as a catalyst and/or a catalyst supportfor many applications, including oxidation chemistry, hydrotreating,Claus reactions, photocatalysis, total oxidation of volatile organiccompounds, and DeNO_(x) reactions. The use of titanium dioxide as acatalyst support for the selective catalytic reduction of NO_(x) istaught in, for example, U.S. Pat. Nos. 4,929,586, and 5,137,855.Although any crystalline form of titanium dioxide (anatase, rutile, andbrookite) may be useful for catalyst applications, anatase is typicallypreferred, see, e.g., U.S. Pat. Nos. 5,330,953 and 6,576,589.

Unfortunately, titanium dioxide is thermally unstable when employed inhigh temperatures applications, such as DeNO_(x). At high temperatures,the titanium dioxide nanoparticles tend to coalesce, which reduces theirsurface area and porosity. Moreover, anatase may be at least partiallyconverted to the less favorable rutile form at high temperature.

A number of strategies have been employed to solve these problems. Oneapproach has been to add a second metal oxide. For example, U.S. Pat.No. 5,021,392 discloses a binary oxide support (titaniumdioxide-zirconia) that is formed from the coprecipitation of salts oftitanium and zirconium to form hydrosol that is aged to produce thebinary oxide support. U.S. Pat. No. 5,922,294 teaches a method of makinga mixed-oxide by co-hydrolysis of a mixture of the alkoxides of titaniumand alumina. U.S. Pub. Appl. No. 2003/0103889 discloses a method to makea titanium dioxide-silica composite that is prepared by combining thetitanium dioxide with a silica sol. When the second metal oxide isincorporated into the titanium dioxide lattice to form a homogenoussingle mixed oxide, the crystal lattice and the catalytic properties oftitanium dioxide are typically affected.

Another approach to solve the thermal instability problem is theapplication of a coating to the titanium dioxide. For example, U.S. Pat.No. 5,330,953 discloses forming two coatings on titanium dioxideparticles that includes a first coating comprising oxides of aluminum,silicon, zirconium and lanthanum and a second phosphate coating. Inaddition, U.S. Pat. No. 5,652,192 discloses a hydrothermal method ofmaking a titanium dioxide nanoparticle coated with sulfate. The methodemploys hydrothermal treatment of a mixture of precursors of titaniumdioxide and sulfate to make titanium dioxide nanoparticles coated withsulfate in crystal form. One problem with this approach is that thecoating can affect the catalytic properties of titanium dioxide.

In sum, a new titanium dioxide nanocomposite particle and processes formaking them are needed. Particularly valuable nanocomposite particleswould have improved thermal stability for catalytic applications.

SUMMARY OF THE INVENTION

The invention is a nanocomposite particle and a process for itsproduction. The nanocomposite particle comprises titanium dioxidenanoparticles, metal oxide nanoparticles, and a surface stabilizer. Themetal oxide nanoparticles are zirconium dioxide, cerium dioxide, hafniumoxide, tin oxide, niobium oxide and/or tantalum oxide. The surfacestabilizer is silicon dioxide, aluminum oxide, phosphorus pentoxide,aluminum silicate and/or aluminum phosphate. The metal oxidenanoparticles are formed by hydrothermally treating an amorphoushydrated metal oxide in the presence of the titanium dioxidenanoparticles.

The nanocomposite particle is prepared by first forming a slurrycomprising titanium dioxide nanoparticles, at least one soluble metaloxide precursor, and a solvent, followed by precipitating the solublemetal oxide precursor to form a slurry comprising titanium dioxidenanoparticles, amorphous hydrated metal oxide and the solvent. Theslurry is then hydrothermally treated to convert the amorphous hydratedmetal oxide to metal oxide nanoparticles and produce the nanocompositeparticle comprising titanium oxide nanoparticles and metal oxidenanoparticles. A surface stabilizer is added before or immediately afterthe hydrothermal treatment.

Surprisingly, the nanocomposite particle exhibits enhanced thermalstability and is an active catalyst support for the DeNO_(x) process.

DETAILED DESCRIPTION OF THE INVENTION

The nanocomposite particle of the invention comprises titanium dioxidenanoparticles, at least one metal oxide nanoparticle, and a surfacestabilizer.

The titanium dioxide nanoparticles of the invention have an averagecrystallite size less than 200 nm, preferably from 1 to 100 nm, and mostpreferably from 2 to 20 nm. The titanium dioxide nanoparticles may be inthe brookite, anatase or rutile phase. However, it is preferred that thetitanium dioxide nanoparticles are predominantly anatase, as determinedby X-ray diffraction patterns. By predominantly anatase, it is meantthat the nanoparticles are at least 95 percent anatase, and mostpreferably greater than 98 percent anatase. The specific surface area ofthe titanium dioxide nanoparticles is typically about 10 to about 300m²/g, preferably from 20 to 200 m²/g.

Suitable titanium dioxide nanoparticles may be purchased from MillenniumChemicals (TIONA® G1) or Kerr McGee (Tronox® Hydrate Paste). Thetitanium dioxide nanoparticles may also be prepared by any process knownin the art. Processes for preparing titanium dioxide nanoparticles arewell known in the art. See, for example, U.S. Pat. No. 4,012,338, whichis incorporated herein by reference.

The nanocomposite particle comprises at least one metal oxidenanoparticle. The metal oxide nanoparticle helps to improve the thermalstability of the titanium dioxide nanoparticles. Suitable metal oxidenanoparticles possess low thermal expansion coefficients, goodmechanical strength, and thermal stability at elevated temperatures. Themetal oxide nanoparticles of the invention include nanoparticles ofzirconium dioxide, cerium dioxide, hafnium oxide, tin oxide, niobiumoxide, tantalum oxide, and mixtures thereof. Preferred metal oxidenanoparticles are zirconium dioxide and cerium dioxide, and mostpreferred are zirconium dioxide nanoparticles. The metal oxidenanoparticles of the invention have an average crystallite size lessthan 200 nm, preferably from 1 to 50 nm, and most preferably from 2 to10 nm.

The nanocomposite particle also contains a surface stabilizer. Thesurface stabilizers of the invention include silicon dioxide, aluminumoxide, phosphorus pentoxide, aluminum silicate, and aluminum phosphate.More preferably, the surface stabilizer is silicon dioxide or aluminumoxide.

The nanocomposite particle preferably contains from 50 to 95 weightpercent titanium dioxide, from 2 to 48 weight percent metal oxide, andfrom 2 to 20 weight percent of the surface stabilizer. More preferably,the nanocomposite particle contains from 60 to 90 weight percenttitanium dioxide, from 4 to 40 weight percent metal oxide, and from 4 to15 weight percent of the surface stabilizer.

The nanocomposite particle of the invention exhibits increased thermalstability. Preferably, the nanocomposite particle has a surface areagreater than 60 m²/g after being calcined at 800° C. for 6 hours.

The metal oxide nanoparticles of the nanocomposite particle are formedby hydrothermally treating an amorphous hydrated metal oxide in thepresence of the titanium dioxide nanoparticles.

The process of preparing the nanocomposite particle begins with firstforming a slurry comprising titanium dioxide nanoparticles, at least onesoluble metal oxide precursor, and a solvent. The order of adding theindividual compounds to the slurry is not critical. For example, thetitanium dioxide nanoparticles may be added to the solvent first,followed by addition of at least one soluble metal oxide precursor.Alternatively, the soluble metal oxide precursor may be added to thesolvent, followed by the titanium dioxide nanoparticles; or the metaloxide precursor and the titanium dioxide nanoparticles may be addedsimultaneously to the solvent; or the solvent may be added to the othertwo components. The formed slurry comprises the dissolved metal oxideprecursor(s) and solid titanium dioxide nanoparticles in the solvent.Preferably, the slurry will be thoroughly mixed to ensure that theslurry is homogeneous and the metal oxide precursor(s) is fullydissolved.

Preferably, the slurry contains from 3 to 30 weight percent of titaniumdioxide nanoparticles, and more preferably 5 to 15 weight percent, basedupon the total weight of the slurry.

The slurry contains at least one metal oxide precursor of zirconiumdioxide, cerium dioxide, hafnium oxide, tin oxide, niobium oxide ortantalum oxide. Metal oxide precursors are metal-containing compounds(zirconium compounds, cerium compounds, aluminum compounds, hafniumcompounds, tin compounds and/or niobium compounds) that form metaloxides when precipitated from the solvent. Although the process of theinvention is not limited by choice of a particular metal oxideprecursor, suitable metal compounds useful in the invention include, butare not limited to, metal halides, metal oxyhalides, metal alkoxides,metal acetates, and metal acetylacetonates of zirconium, cerium,hafnium, tin, niobium and tantalum. For example, zirconiumtetrachloride, tantalum oxytrichloride, cerium acetate, niobiumacetylacetonate, and tin tetraethoxide may be used.

The solvent is any liquid that is capable of dissolving the metal oxideprecursor(s). Preferably, the solvent is water. However, nonaqueousprotic solvents with high dielectric constants are also suitable.Preferred nonaqueous protic solvents are alcohols. Preferred alcoholsinclude lower aliphatic C₁-C₄ alcohols such as methanol, ethanol,isopropanol, tert-butanol, and mixtures thereof. Blends of water and oneor more nonaqueous protic solvents may also be employed.

After forming the slurry, the soluble metal oxide precursor is thenprecipitated from the slurry to form an amorphous hydrated metal oxide.Any suitable method that is capable of precipitating an amorphoushydrated metal oxide from solution may be employed in the process of theinvention. For example, pH shift, solvent shift, ion exchange to forminsoluble salts or hydroxides, condensation reactions, and thermalhydrolysis techniques may be employed. Preferably, the pH of the slurryis adjusted to a pH of 7 to 10 by adding an acid or base that is capableof precipitating the metal oxide from the slurry. The pH adjustingsubstance is preferably a base, or an acid, that will be decomposedduring post treatment, e.g., by calcination of the nanocompositeparticle. Suitable bases include amines, ammonia, and any organic basewith pK_(a) of 9.0 or greater. Ammonia is most preferred. Any inorganicor organic acid may also be employed. Preferred acids include nitricacid, sulfuric acid and hydrochloric acid; nitric acid is mostpreferred.

Following precipitation, the slurry comprises titanium dioxidenanoparticles, amorphous hydrated metal oxide and the solvent. Theamorphous hydrated metal oxide may be deposited on the surface of thetitanium dioxide nanoparticles, free-floating in the slurry, or amixture of both.

Following the precipitation step, the slurry is hydrothermally treatedin order to convert the amorphous hydrated metal oxide to metal oxidenanoparticles and produce a nanocomposite particle comprising titaniumoxide nanoparticles and metal oxide nanoparticles. The hydrothermaltreatment consists of heating the slurry to a high temperature,preferably at elevated pressure. Preferably, the slurry is heated to atemperature from 60° C. to 250° C. and at a pressure of from 20 to 500psig. More preferably, the slurry is heated to a temperature from 80° C.to 130° C. and at a pressure of from 20 to 200 psig.

Preferably, the slurry is hydrothermally treated for a period of timebetween 3 to 24 hours, however the time is not critical. Thetemperature, pressure and the time of hydrothermal treatment must besufficient for the nucleation and growth of metal oxide nanoparticles.One advantage of the hydrothermal process is that it forms metal oxidenanoparticles under relatively mild reaction conditions which mayminimize any effect on the surface properties and crystal structure ofthe titanium dioxide nanoparticles.

The surface stabilizer is added before or immediately after thehydrothermal treatment. In one method, the surface stabilizer may beadded to the slurry at any time prior to the hydrothermal treatment. Forinstance, the surface stabilizer may be added to the slurry prior toprecipitating the amorphous hydrated metal oxide or following theprecipitation of the amorphous hydrated metal oxide. The slurry willthen be processed in the manner described above. Alternatively, thesurface stabilizer may be added immediately after the hydrothermaltreatment, i.e., prior to separation of the nanocomposite particleproduct from the solvent, and optional calcination. Preferably, thesurface stabilizer will be added to slurry with thorough mixing.Typically, the slurry is mixed for a period of one minute to three hoursfollowing surface stabilizer addition. Suitable compounds for thesurface stabilizer include amorphous silicon dioxide, includingcolloidal silicon dioxide, halides or alkoxides of silicon and aluminum,and aluminum phosphate.

Following hydrothermal treatment, the nanocomposite particle product ispreferably separated from the solvent by any means (e.g., filtration,decantation, centrifugation, and the like), washed with water, anddried. Preferably, the nanocomposite particle is calcined by firing atan elevated temperature. Calcination may be performed in the presence ofoxygen (from air, for example) or an inert gas which is substantiallyfree of oxygen such as nitrogen, argon, neon, helium or the like ormixture thereof. Optionally, the calcination may be performed in thepresence of a reducing gas, such as carbon monoxide. The calcination ispreferably performed at a temperature of at least 250° C. Morepreferably, the calcination temperature is at least 300° C. but notgreater than 1000° C. Typically, calcination times of from about 0.5 to24 hours will be sufficient.

The invention also comprises a catalyst containing the nanocompositeparticle. The catalyst comprises the nanocomposite particle and at leastone metal component. The metal component comprises one or more metals,including platinum, gold, silver, palladium, copper, tungsten,molybdenum, vanadium, iron, rhodium, nickel, manganese, chromium,cobalt, and ruthenium. The metal component may be the metal itself orany compound that contains the metal. Preferably, the metal component isa metal oxide.

Typically, the amount of metal present in the catalyst will be in therange of from 0.001 to 30 weight percent, preferably 0.005 to 20 weightpercent, and particularly 0.01 to 10 weight percent, based upon thetotal weight of the catalyst.

The catalyst can be prepared by any suitable method. In one method, themetal component is added during the preparation of the nanocompositeparticle itself. For instance, the metal component may be added to theslurry before or after the hydrothermal treatment and processed in thesame manner as described above. Alternatively, the metal component canbe deposited directly onto the nanocomposite particle. For example, themetal component may be supported on the nanocomposite particle byimpregnation, adsorption, precipitation, or the like.

Suitable metal components include the metals themselves, in addition tothe metal alkoxides such as tungsten ethoxide, metal halides such astungsten chloride, metal oxyhalides such as tungsten oxychloride,metallic acids such as tungstic acid, and metal oxides such as ammoniumtungstate, vanadium pentoxide, molybdenum oxide and copper monoxide.

Preferred catalysts contain tungsten trioxide and/or vanadium pentoxide.Preferably, the catalyst comprises 0.1 to 10 weight percent vanadiumpentoxide and 4 to 20 weight percent of tungsten trioxide, morepreferably between 0.2 to 7 weight percent vanadium pentoxide andbetween 4 to 16 weight percent tungsten trioxide, and most preferablybetween 0.2 to 5 weight percent vanadium pentoxide and 5 to 12 weightpercent tungsten trioxide.

The nanocomposite particle can be calcined before or after the additionof the metal component. The temperature at which the nanocompositeparticle is calcined depends on the end use for which it is intended.Preferably, the calcination is performed at a temperature from 400° C.to 900° C., more preferably from 600° C. to 800° C., and most preferablyfrom 650° C. to 750° C.

The catalyst is particularly useful in DeNO_(x) applications. TheDeNO_(x) application comprises contacting a waste stream containingnitrogen oxides with the catalyst to reduce the amount of nitrogenoxides in the waste stream. Such applications are well known in the art.In this process, nitrogen oxides are reduced by ammonia (or anotherreducing agent such as unburned hydrocarbons present in the waste gaseffluent) in the presence of the catalyst with the formation ofnitrogen. See, for example, U.S. Pat. Nos. 3,279,884, 4,048,112 and4,085,193, the teachings of which are incorporated herein by reference.

The following examples merely illustrate the invention. Those skilled inthe art will recognize many variations that are within the spirit of theinvention and scope of the claims.

Example 1 Nanocomposite Preparation

Nanocomposite 1A

Titanium Dioxide Nanoparticle Preparation: A TiSO₄ solution (2000 g, 7.6wt. % TiO₂) is charged to a 3-L reactor and the pH of the solution isadjusted to about 1 with an ammonium hydroxide solution (29% NH₃ inwater, product of Aldrich) under constant stirring at room temperature.Urea (550 g) is then dissolved in the solution and the temperature israised to 98° C. for 3 h. After cooling, the titanium dioxidenanoparticles are separated by filtration and washed with water. Thefiltered titanium nanoparticles are redispersed in water to form a 2-Lslurry.

Nanocomposite Preparation: One half of the 2-L slurry is added to a 2-Lbeaker and ZrOCl₂.8H₂O (50 g) is dissolved in the slurry. Under strongagitation, an ammonium hydroxide solution (29% NH₃ in water) is addedslowly until the pH of the slurry is about 10 and the ZrO₂ precipitates.Fumed SiO₂ (5 g) is then added to the slurry, the slurry is charged to a2-L stirred hydrothermal reactor and hydrothermally treated at 90° C.for 12 h. The product is cooled, separated by filtration and washed withwater. The washed cake is dried in an oven at 100° C. for 12 hours andcalcined in a furnace at 800° C. for 6 hours to produce Nanocomposite1A.

Nanocomposites 1B-1H:

The nanocomposite particle procedure of Nanocomposite 1A above isfollowed except that a commercial TiO₂ nanoparticle (Millennium TionaG1) is used. Particles 1B, 1C, and 1D, 1E, and 1F use fumed SiO₂ assurface stabilizer, Particle 1G uses SiO₂ sol as surface stabilizer, andParticle 1H uses aluminum phosphate as the surface stabilizer. Theamounts of TiO₂, ZrO₂ and surface stabilizer are varied to provideNanocomposite 1B, 1C, 1D, 1E, 1F, 1G and 1H of varying composition.

Comparative Nanocomposites 1I-1J:

The nanocomposite particle procedure of Nanocomposite 1B is followedexcept that ZrO₂ is omitted for Nanocomposite 1I, and SiO₂ is omittedfor Nanocomposite 1J.

The resulting nanocomposites (following calcination at 800° C.) areanalyzed for composition, surface area, pore volume and TiO₂ and ZrO₂crystal size measurement. See Table 1 for the results.

The formation of the metal oxide nanoparticles following thehydrothermal treatment was confirmed by x-ray diffraction testing. Priorto the hydrothermal treatment, only the titanium dioxide nanoparticleswere detected by x-ray diffraction. Following the hydrothermaltreatment, a second crystal phase is detected corresponding to the metaloxide nanoparticles.

Example 2 DeNO_(x) Catalyst Preparation

The catalyst is prepared according to the procedure described inco-pending U.S. application Ser. No. 10/968,706. The nanocomposite (75g) is slurried in deionized water (175 mL) and concentrated sulfuricacid is added until the pH reaches 0. An ammonium paratungstate solution(9.38 g AMT in 150 mL deionized water, formed by mixing at 50° C.) isadded to the nanocomposite slurry and mixed for 1 h. The powder isfiltered, dried at 110° C. overnight, and then calcined at 500° C. for 6h. The powder (10 g) is then added to a vanadium oxide solution (0.185 gmonoethanolamine and 0.092 g V₂O₅ in 20 mL deionized water, formed bymixing at 60° C. until dissolution) and stirred for 10 min. The solventis evaporated under vacuum and the solid is dried at 110° C. overnight,and then calcined at 600° C. for 6 h. The catalysts containedapproximately 10 wt. % WO₃ and 0.9 wt. % V₂O₅.

Nanocomposites 1A, 1B, 1C, 1D, 1E, 1F, 1G, 1H, 1I, and 1J are used toform Catalysts 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, 2I, and 2J, respectively.

Example 3 DeNO_(x) Test

The catalysts are loaded into a conventional plug flow reactor with afeed consisting of 300 ppm NO, 360 ppm NH₃, 3% O₂, 10% H₂O and balanceN₂ at a space velocity is 80,000/hr. The NH₃ catalytic reduction isperformed at 270° C. and 320° C.

The results are shown in Table 2. The results are recorded as percent NOconversion and activity. The activity is expressed as k*tau where k*taurepresents the activity constant multiplied by the contact time. It isgenerally accepted that ammonia (NH₃) selective catalytic reduction isfirst order with respect to NO, and zero order with respect to NH₃.Therefore, the activity is calculated from conversion ask*tau=−ln(1−conversion) where conversion is represented as a fraction of1.

TABLE 1 Amounts of TiO₂, ZrO₂ and Surface Stabilizer in theNanocomposite Particles SiO₂ or Crystal size TiO₂ ZrO₂ AlPO₄ S.A. P.V.(nm) Nano. # (wt. %) (wt. %) (wt. %) (m2/g) (cm3/g) TiO₂ ZrO₂ 1A 76 19 5156 0.33 6.8 — 1B 90 5 5 97 0.39 17.0 6.8 1C 80 15 5 109 0.76 14.5 6.21D 70 25 5 112 0.78 14.6 6.4 1E 55 40 5 110 0.65 14.5 7.3 1F 75 15 10133 0.75 12.4 5.7 1G 75 15 10 143 0.71 10.8 4.0 1H 80 15 5 98 0.76 15.86.7 1I * 95 0 5 78 0.30 19.8 1J * 80 20 0 51 0.67 21.9 11.4 *Comparative Example

TABLE 2 DeNO_(x) Results 270° C. Runs 320° C. Runs NO ConversionActivity NO Conversion Activity Catalyst (%) (k * tau) (%) (k * tau) 2A39.6 0.504 70.6 1.224 2B 77.9 1.511 91.7 2.492 2C 59.5 0.903 91.4 2.4522D 64.2 1.028 88.1 2.13 2E 55.0 0.80 77.0 1.470 2F 44.9 0.596 84.6 1.8702G 39.6 0.504 70.9 1.234 2H 59.9 0.915 82.3 1.732 2I * 54.8 0.795 74.61.369 2J * 53.5 0.765 72.1 1.277 * Comparative Example

What is claimed is:
 1. A process for reducing nitrogen oxides in a wastestream by: contacting the waste stream with a catalyst, wherein thecatalyst includes: (A) a nanocomposite particle, the nanocompositeparticle comprising: (i) predominantly anatase titanium dioxidenanoparticles; (ii) metal oxide nanoparticles selected from the groupconsisting of zirconium dioxide, cerium dioxide, hafnium oxide, tinoxide, niobium oxide, tantalum oxide, and combinations thereof; and(iii) a surface stabilizer selected from the group consisting of silicondioxide, aluminum oxide, phosphorus pentoxide, aluminum silicate andaluminum phosphate, and combinations thereof; and (B) at least one metalcomponent comprising a metal selected from the group consisting ofplatinum, gold, silver, palladium, copper, tungsten, molybdenum,vanadium, iron, rhodium, nickel, manganese, chromium, cobalt, ruthenium,and combinations thereof.
 2. The process of claim 1, wherein the atleast one metal component is selected from the group consisting oftungsten and vanadium.
 3. The process of claim 2, wherein the catalystcomprises about 0.1 to about 10 weight percent vanadium and about 4 toabout 20 weight percent tungsten.
 4. The process of claim 1, wherein themetal oxide nanoparticles are zirconium dioxide.
 5. The process of claim1, wherein the nanocomposite particles comprise about 50 to about 95weight percent of titanium dioxide nanoparticles, about 2 to about 48weight percent metal oxide nanoparticles, and about 2 to about 20 weightpercent surface stabilizer.
 6. The process of claim 1, wherein thenanocomposite particle has a surface area greater than about 60 m²/gafter being calcined at 800° C. for six hours.